Multiple in-flow control devices and methods for using same

ABSTRACT

An apparatus controls flow of a fluid between a wellbore tubular and a wellbore using a particulate control device configured to be disposed in the wellbore and at least two parallel and directionally opposing flow paths in fluid communication with the particulate control device.

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The disclosure relates generally to systems and methods for selectivecontrol of fluid flow into a production string in a wellbore.

2. Description of the Related Art

Hydrocarbons such as oil and gas are recovered from a subterraneanformation using a wellbore drilled into the formation. Such wells aretypically completed by placing a casing along the wellbore length andperforating the casing adjacent each such production zone to extract theformation fluids (such as hydrocarbons) into the wellbore. Theseproduction zones are sometimes separated from each other by installing apacker between the production zones. Fluid from each production zoneentering the wellbore is drawn into a tubing that runs to the surface.It is desirable to control drainage along the production zone or zonesto reduce undesirable conditions such as an invasive gas cone, watercone, and/or harmful flow patterns.

The present disclosure addresses these and other needs of the prior art.

SUMMARY OF THE DISCLOSURE

In aspects, the present disclosure provides an apparatus for controllinga flow of a fluid between a wellbore tubular and a wellbore. Theapparatus may include a particulate control device configured to bedisposed in the wellbore; and at least two parallel and directionallyopposing flow paths in fluid communication with the particulate controldevice.

In aspects, the present disclosure also provides a method forcontrolling a flow of a fluid between a wellbore tubular and a wellboreannulus. The method may include separating a fluid flowing from aformation surrounding the wellbore into at least two parallel streamsflowing in opposing directions; and generating a pressure drop in the atleast two streams.

In aspects, the present disclosure further provides a method forcontrolling a flow of a fluid between a wellbore tubular and a wellbore.The method may include separating a fluid flowing between the wellboreannulus and a bore of the wellbore tubular into at least two parallelstreams flowing in opposing directions; and generating a pressure dropin the at least two streams.

It should be understood that examples of the more important features ofthe disclosure have been summarized rather broadly in order thatdetailed description thereof that follows may be better understood, andin order that the contributions to the art may be appreciated. Thereare, of course, additional features of the disclosure that will bedescribed hereinafter and which will form the subject of the claimsappended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages and further aspects of the disclosure will be readilyappreciated by those of ordinary skill in the art as the same becomesbetter understood by reference to the following detailed descriptionwhen considered in conjunction with the accompanying drawings in whichlike reference characters designate like or similar elements throughoutthe several figures of the drawing and wherein:

FIG. 1 is a schematic elevation view of an exemplary multi-zonalwellbore and production assembly which incorporates an inflow controlsystem in accordance with one embodiment of the present disclosure;

FIG. 2 is a schematic elevation view of an exemplary open holeproduction assembly which incorporates an inflow control system inaccordance with one embodiment of the present disclosure;

FIG. 3 is a sectional view of an exemplary production control devicemade in accordance with one embodiment of the present disclosure;

FIG. 4 is schematic illustration of an in-flow control in a conventionalwell; and

FIG. 5 is a schematic view of an in-flow control device made inaccordance with one embodiment of the present disclosure deployed in ahigh fluid flow velocity situation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present disclosure relates to devices and methods for controllingproduction of a subsurface fluid. In several embodiments, the devicesdescribe herein may be used with a hydrocarbon producing well. In otherembodiments, the devices and related methods may be used in geothermalapplications, ground water applications, etc. The present disclosure issusceptible to embodiments of different forms. There are shown in thedrawings, and herein will be described in detail, specific embodimentsof the present disclosure with the understanding that the presentdisclosure is to be considered an exemplification of the principles ofthe disclosure, and is not intended to limit the disclosure to thatillustrated and described herein. Further, while embodiments may bedescribed as having one or more features or a combination of two or morefeatures, such a feature or a combination of features should not beconstrued as essential unless expressly stated as essential.

Referring initially to FIG. 1, there is shown an exemplary wellbore 10that has been drilled through the earth 12 and into a pair of formations14, 16 from which it is desired to produce hydrocarbons. The wellbore 10is cased by metal casing, as is known in the art, and a number ofperforations 18 penetrate and extend into the formations 14, 16 so thatproduction fluids may flow from the formations 14, 16 into the wellbore10. The wellbore 10 has a deviated or substantially horizontal leg 19.The wellbore 10 has a late-stage production assembly, generallyindicated at 20, disposed therein by a tubing string 22 that extendsdownwardly from a wellhead 24 at the surface 26 of the wellbore 10. Theproduction assembly 20 defines an internal axial flow bore 28 along itslength. An annulus 30 is defined between the production assembly 20 andthe wellbore casing. The production assembly 20 has a deviated,generally horizontal portion 32 that extends along the deviated leg 19of the wellbore 10. Production nipples 34 are positioned at selectedpoints along the production assembly 20. Optionally, each productionnipple 34 is isolated within the wellbore 10 by a pair of packer devices36. Although only a few production nipples 34 are shown in FIG. 1, theremay, in fact, be a large number of such nipples arranged in serialfashion along the horizontal portion 32.

Each production nipple 34 features a production control device 38 thatis used to govern one or more aspects of a flow of one or more fluidsinto the production assembly 20. As used herein, the term “fluid” or“fluids” includes liquids, gases, hydrocarbons, multi-phase fluids,mixtures of two of more fluids, water, brine, engineered fluids such asdrilling mud, fluids injected from the surface such as water, andnaturally occurring fluids such as oil and gas. In accordance withembodiments of the present disclosure, the production control device 38may have a number of alternative constructions that ensure selectiveoperation and controlled fluid flow therethrough.

FIG. 2 illustrates an exemplary open hole wellbore 11 wherein theproduction devices of the present disclosure may be used. Constructionand operation of the open hole wellbore 11 is similar in most respectsto the wellbore 10 (FIG. 1) described previously. However, the wellborearrangement 11 has an uncased borehole that is directly open to theformations 14, 16. Production fluids, therefore, flow directly from theformations 14, 16, and into the annulus 30 that is defined between theproduction assembly 21 and the wall of the wellbore 11. There are noperforations, and the packers 36 may be used to separate the productionnipples. However, there may be some situations where the packers 36 areomitted. The nature of the production control device is such that thefluid flow is directed from the formation 16 directly to the nearestproduction nipple 34.

Referring now to FIG. 3, there is shown one embodiment of a productionor injection control device 100 for controlling the flow of fluidsbetween a reservoir and a flow bore 102 of a tubular 104 along aproduction string (e.g., tubing string 22 of FIG. 1). The controldevices 100 may be distributed along a section of a production well toprovide fluid control at multiple locations. This can be useful, forexample, to impose a desired drainage or production influx pattern. Byappropriately configuring the production control devices 100, a wellowner can increase the likelihood that an oil or gas bearing reservoirwill drain efficiently. This drainage pattern may include equal drainagefrom all zones or individualized and different drainage rates for one ormore production zones. During injection operations, wherein a fluid suchas water or steam is directed into the reservoir, the devices 100 may beused to distribute the injected fluid in a desired manner. Exemplaryproduction control devices are discussed herein below.

In one embodiment, the production control device 100 includes aparticulate control device 110 for reducing the amount and size ofparticulates entrained in the fluids and in-flow control devices 120 a,bthat control overall drainage rate from the formation. The particulatecontrol device 110 can include known devices such as sand screens andassociated gravel packs. In embodiments, the in-flow control devices 120a,b utilizes flow channels and/or other geometries that control in-flowrate and/or the type of fluids entering the flow bore 102 of a tubular104 via one or more flow bore openings 106. Illustrative embodiments aredescribed below.

In one embodiment, the in-flow control devices 120 a and 120 b arepositioned at opposing ends of the particulate control device 110. Thein-flow control devices 120 a,b each include flow passages 122 a,b thatmay include channels, orifices bores, annular spaces and/or hybridgeometry, that are constructed to generate a desired pressuredifferential across the in-flow devices 120 a,b. By hybrid, it is meantthat a give flow passage may incorporate two or more differentgeometries (e.g., shape, dimensions, etc.). The flow passages 122 a,bare configured to convey fluid between the particulate control device110 and the flow bore 102 along parallel and directionally opposing flowpaths. By parallel, it is meant that the flow paths have a common originand end point. By directionally opposing, it is meant that the flowpassage 122 a directs the fluid in an axial direction opposite to theaxial direction of the fluid in the flow passage 122 b. It should beunderstood, however, that the flow passages 122 a,b may utilize helicalchannels, radial channels, circular channels, etc. That is, the flowdirection of the flow passages 122 a,b may use directional components inaddition to an axial component. Also, in embodiments, the pressurecontrol may be configured such that the pressure drop along theparticulate control device 110 is substantially lower than the pressuredrop in the pressure drop along the in-flow control devices 120 a, 120b. This pressure drop may be the drop associated with the fluid flowingthrough the wall of the filtration media (e.g., the screen) and/or thefluid flowing between the wall of the filtration media and the base pipe108. By “substantially,” it is meant an order of magnitude lowerpressure drop. It should be noted that the fluid flow along theparticulate control device 110 also has portions wherein two or morefluids streams have parallel and directionally opposite flows. That is,the flow paths between the base pipe 108 and the wall of the particulatecontrol device 110 may direct flow substantially parallel to the longaxis of the tool and in opposing directions.

During one exemplary use, a fluid F (liquid, gas, steam or mixture) mayinitially flow radially into the particulate control device 110 andsplit into a first fluid stream F1 and a second fluid stream F2. Thefluid stream F1 flows through the inflow control device 120 a, whichcauses a pre-determined pressure drop in the fluid stream F1.Thereafter, the fluid stream flows through openings 106 into the flowbore 102. Similarly, the fluid stream F2 flows through the inflowcontrol device 120 b, which causes a pre-determined pressure drop in thefluid stream F2. Thereafter, the fluid stream flows through openings 106into the flow bore. The pressure drops in the fluid streams F1 and F2may be the same or different. It should be noted that no fluid entersthe flow bore 102 radially through a section 108 of the base pipe thatis radially inward of the particulate control device 110. That is, allthe fluid enters the flow bore at a location either uphole or downholeof the particulate control device 110.

While the teachings of the present disclosure may be applied to avariety of situations, certain embodiments of the present disclosure maybe useful in controlling inflow patterns in relatively high-velocityflow rate situations. Referring now to FIG. 4, there is shown aproduction control device 150 disposed in a wellbore. The in-flowcontrol device 150 may include a particulate control device 152 and anin-flow control device 154. A permeable material 156 may partially orcompletely fill an annular space 157 surrounding the particulate controldevice 152. This permeable material 156 may be a naturally occurringmaterial such as sand that, over time, invaded the wellbore 152. Thepermeable material 156 may also be an engineered material such as gravelthat has been pumped in from the surface. The permeable material 156 mayact as a modulating media that moderates or distributes fluid flow 158across the axial length of the particulate control device 152. Thus, thevelocity of the fluid 160 flowing into the juncture 162 between theparticulate control device 152 and the in-flow control device 154 may besignificantly greater than the fluid inflow velocity at a distal point164 on the particulate control device.

Referring now to FIG. 5, there is shown the FIG. 3 embodiment whereinthe in-flow control devices 120 a and 120 b are positioned at opposingends of the particulate control device 110. The annular space 170 aroundthe particulate control device 110 does not include a flow modulatingmedia. Rather, the annular space 170 may be open (standalonecompletion), include a material that is functionally the equivalent ofan open space or include a permeable material (gravel pack completion),at least in terms of providing resistance to fluid flow. For purposes ofthis disclosure, the functional equivalent of an open space may be amaterial having a permeability of no less than 50 Darcy or a materialthat does not offer flow resistance in the radial and lineal direction.

In one situation, the formation may produce a fluid at a relatively highvelocity, e.g., a gas or steam 172. It will be appreciated that if onlyone in-flow control device was present, e.g., in-flow control device 120a, then all of the gas 172 would flow through the juncture 174 betweenthe particulate control device 110 and the in-flow control device 120 a.The relatively high velocity may cause undesirable corrosion and/orerosion in the vicinity of the junction 174. Because two in-flow controldevices are present, the gas 172 is divided into two streams 176 and178. In one arrangement, each stream 176, 178 has one-half of the volumeof the gas 172. Thus, the flow velocity at the juncture 174 has beenreduced by approximately one-half, which reduces the amount of possiblematerial degradation in the vicinity of the juncture 174. Additionalin-flow control device can be considered but the solution will berestricted by the joint length.

From the above, it should be appreciated that what has been describedincludes, in part, an apparatus for controlling a flow of a fluidbetween a wellbore tubular and a wellbore annulus. The apparatus mayinclude a particulate control device configured to be disposed in thewellbore; and two (or more) parallel and directionally opposing flowpaths in fluid communication with the particulate control device. Theflow paths may be configured to generate a substantially greaterpressure drop than the particulate control device. A first flow path ofthe flow paths may be in fluid communication with a first end of theparticulate control device and a second flow path of the flow paths maybe in fluid communication with a second end of the particulate controldevice. The first and second ends may at opposite ends of theparticulate control device. The particulate control device may include afluid impermeable base pipe portion that may be radially inward of theparticulate control device. The flow paths may be configured to generatea minimum flow into the particulate control device at a substantiallymedial location along the particulate control device. The particulatecontrol device may be configured to generate fluid streams flowing inaxially opposing directions.

From the above, it should be appreciated that what has been describedalso includes, in part, a method for controlling a flow of a fluidbetween a wellbore tubular and a wellbore annulus. The method mayinclude separating a fluid flowing from a formation surrounding thewellbore into two (or more) parallel streams flowing in opposingdirections; and generating a pressure drop in the streams. The methodmay include filtering the fluid before separating the fluid intoparallel streams. The method may also include generating a substantiallygreater pressure drop in the streams than during filtering. The fluidmay be filtered at a selected location in the wellbore, and the pressuredrops may be generated uphole and downhole of the selected location. Themethod may include receiving a gas from the formation, the gas being thefluid. Also, the gas may be received through an open annular space.

From the above, it should be appreciated that what has been describedfurther includes, in part, a method for control a flow of a fluidbetween a wellbore tubular and a wellbore annulus. The method mayinclude separating a fluid flowing between the wellbore annulus and abore of the wellbore tubular into two (or more0 parallel streams flowingin opposing directions; and generating a pressure drop in the streams.

It should be understood that the teachings of the present disclosure mayreadily be applied to other situations such as geothermal wells, waterproducing wells, etc.

For the sake of clarity and brevity, descriptions of most threadedconnections between tubular elements, elastomeric seals, such aso-rings, and other well-understood techniques are omitted in the abovedescription. Further, terms such as “slot,” “passages,” and “channels”are used in their broadest meaning and are not limited to any particulartype or configuration. The foregoing description is directed toparticular embodiments of the present disclosure for the purpose ofillustration and explanation. It will be apparent, however, to oneskilled in the art that many modifications and changes to the embodimentset forth above are possible without departing from the scope of thedisclosure.

What is claimed is:
 1. An apparatus for controlling a flow of a fluidbetween a wellbore tubular and a wellbore annulus, comprising: aparticulate control device configured to be disposed in the wellbore;and at least two parallel and directionally opposing flow paths in fluidcommunication with the particulate control device.
 2. The apparatusaccording to claim 1 wherein the at least two flow paths are configuredto generate a substantially greater pressure drop than the particulatecontrol device.
 3. The apparatus according to claim 1, wherein a firstflow path of the at least two flow paths is in fluid communication witha first end of the particulate control device and a second flow path ofthe at least two flow paths is in fluid communication with a second endof the particulate control device, the first and second ends being atopposite ends of the particulate control device.
 4. The apparatusaccording to claim 1, wherein the particulate control device includes afluid impermeable base pipe portion radially inward of the particulatecontrol device.
 5. The apparatus according to claim 1, wherein the atleast two flow paths are configured to generate a minimum flow into theparticulate control device at a substantially medial location along theparticulate control device.
 6. The apparatus according to claim 1,wherein the particulate control device is configured to generate twofluid streams flowing in axially opposing directions.
 7. A method forcontrolling a flow of a fluid between a wellbore tubular and a wellboreannulus, comprising: separating a fluid flowing from a formationsurrounding the wellbore into at least two parallel streams flowing inopposing directions; and generating a pressure drop in the at least twostreams.
 8. The method according to claim 7, further comprisingfiltering the fluid before separating the fluid into at least twoparallel streams.
 9. The method according to claim 8 further comprisinggenerating a substantially greater pressure drop in the at least twostreams than during filtering.
 10. The method according to claim 8,wherein the fluid is filtered at a selected location in the wellbore,and the pressure drops are generated uphole and downhole of the selectedlocation.
 11. The method according to claim 7, further comprisingreceiving a gas from the formation, the gas being the fluid.
 12. Themethod according to claim 11, wherein the gas is received through anopen annular space.
 13. The method according to claim 7, wherein aparticulate control device is configured to separate the fluid.
 14. Amethod for controlling a flow of a fluid between a wellbore tubular anda wellbore annulus, comprising: separating a fluid flowing between thewellbore annulus and a bore of the wellbore tubular into at least twoparallel streams flowing in opposing directions; and generating apressure drop in the at least two streams.
 15. The method according toclaim 14, further comprising filtering the fluid before separating thefluid into at least two parallel streams.
 16. The method according toclaim 15 further comprising generating a substantially greater pressuredrop in the at least two streams than during filtering.
 17. The methodaccording to claim 8, further comprising flowing the fluid from the boreof the wellbore tubular to the wellbore annulus.